US20160059972A1 - Method and apparatus for boxing rectangular articles - Google Patents

Abstract

A rectangular article boxing method of the present invention includes: a step of erecting upright and aligning a bundle of rectangular articles, gripping, lifting, transferring, and lowering the bundle and inserting the bundle between a first guide and a second guide disposed at a predetermined interval in a carton; a step of displacing the first guide to above the upright bundle; a step of moving the inserted bundle to a position in contact with the existing bundle and holding the bundles with the second guide; a step of holding the upright bundles with the first guide in place of the second guide; and a step of displacing the second guide to a position at the predetermined interval from the first guide to receive the bundle to be conveyed next.

Description

TECHNICAL FIELD
• The present invention relates to a rectangular article boxing method for boxing, in an upright state in a carton, a bound plurality of rectangular articles such as a standing pouch and an apparatus for carrying out the method.
BACKGROUND ART
• A rectangular article such as a pouch to be filled with a liquid cleaning agent is boxed and shipped from a pouch manufacturing factory. A plurality of pouches manufactured in a manufacturing line (a pouch manufacturing process) are bound and sequentially packed in a box body. As one of packing forms, there is a form usually called “vertical loading” for inserting pouch bundles of pouches (usually, twenty-five to fifty pouches are bundled as one batch) into a carton in an upright state.
• A problem in automating the packing of this vertical loading is that, in a process for inserting the pouch bundle into the carton, a preceding batch already inserted into the carton and the present batch cause interference. In particular, a standing pouch such as a pouch with a spout section has a bottom material. A bottom section of the pouch is approximately twice as thick as the other portion. Therefore, after the insertion into the carton, a phenomenon tends to occur in which, because of a shift due to swelling of the pouch bundle, alignment is disordered and the pouch bundle cannot be stored in a desired position in the carton, the pouch bundle conveyed in the next batch hits the pouch bundle of the preceding batch, and the pouch bundles are not neatly inserted into the carton. Because of such a reason, conventionally, the automatic packing of the standing pouch form is difficult and manual boxing has been performed.
• Under such circumstances,Patent Document 1 has been proposed that has a purpose of providing a pouch automatic packing method for bundling, in particular, pouch having different vertical thicknesses, loading the pouches in a container in an aligned state automatically and not to cause load shifting even after storage, and automatically packing the pouches, an apparatus for the pouch automatic packing method, and a robot hand apparatus of a robot used in the asparagus. The pouch automatic packing method of the invention includes a step of binding a plurality of stacked pouches, a step of loading two bundles of the bound pouches bundles one on top of the other with directions thereof changed from each other on a tray conveyed by a tray conveying apparatus, a step of placing a pat on the upper surface of the pouch bundles transferred onto the tray, and a container storage step of gripping, from the tray, with the robot, a pouch bundle group on which the pat is placed and sequentially loading and storing the pouch bundles in a container for pouch transportation. Two pouch bundles overlapping each other vertically reversely in the container is set as one stage. The pouch bundles are automatically stored and packed in a state in which the pouch bundles are stacked with pats interposed among stages. However, the pouch automatic packing method requires manual work for manually bundling a predetermined number of, for example, fifty pouches discharged from a pouch manufacturing machine and, after inspection, inserting the pouches into a packet of a binding apparatus in a state in which the pouches are bundled in the same direction. The pouch automatic packing method also requires work for inserting the bundled pouches into the packet and binding the bundled pouches with the binding apparatus to bind the bundled pouches as one pouch bundle.
CITATION LISTPatent Document
• Patent Document 1: Japanese Patent Application Laid-Open No. H10-16910 “Pouch Automatic Packing Method and Apparatus therefor, and Robot Hand Apparatus of Pouch Loading Robot” Laid open on Jan. 20, 1998
SUMMARY OF THE INVENTIONProblems to be Solved by the Invention
• In the technique ofPatent Document 1, the two pouch bundles are automatically laid one on top of the other with the directions thereof changed, the pad is placed on the pouch bundles, and the pouch bundles are gripped by the robot hand apparatus and loaded in the container. Therefore, even the packaging pouches in the standing form, which are slippery and automatic packing of which is difficult in the past, can be surely aligned and automatically packed. An effect can be attained that, compared with the past, manpower can be greatly saved and production costs can be reduced. However, as explained above, not only the manual work is partially required but also the operation for banding the pouches and binding the pouches into one pouch bundle with a binding apparatus is required.
• It is an object of the present invention to solve the problems, that is, provide a rectangular article boxing method for handling bundles of rectangular articles such as packaging pouches, in particular, packing pouches in a standing form while keeping the bundles free without binding the bundles one by one, and for realizing consistently and completely automated boxing, and an apparatus for the method.
Means for Solving the Problems
• A rectangular article boxing method of the present invention includes: a step of erecting upright and aligning a bundle of rectangular articles, gripping, lifting, transferring, and lowering the bundle using a multi-axis actuator and a hand, and inserting the bundle between a first guide and a second guide disposed at a predetermined interval in a carton; a step of displacing the first guide to above the upright bundle; a step of moving the inserted bundle to a position in contact with the existing bundle and holding the bundles with the second guide; a step of holding the upright bundles with the first guide in place of the second guide; and a step of displacing the second guide to a position at the predetermined interval from the first guide to receive the bundle to be conveyed next.
• A rectangular article boxing apparatus of the present invention includes: an aligning device that erects upright and aligns a bundle of rectangular articles; a hand that grips the upright bundle; a multi-axis actuator that lifts the hand and transfers the hand to a carton placing position and lowers the hand; a first guide and a second guide disposed at a predetermined interval in a carton; and a mechanism for controlling drive of the first guide and the second guide such that the first guide is displaced to above the upright bundle, the second guide moves the inserted bundle to a position in contact with the existing bundle and holds the bundles, subsequently the first guide holds the upright bundles in place of the second guide, and the second guide is displaced to a position at the predetermined interval from the first guide to receive the bundle to be conveyed next.
• In one form of the apparatus according to the present invention, the first guide and the second guide are formed in L shapes opposed to each other, and opposing portions of the first guide and the second guide are formed in a comb teeth shape such that the displacement of the first guide and the displacement of the second guide can cross without interfering with each other.
• In one form of the apparatus according to the present invention, the apparatus includes lining carrying-in means in the vicinity of carton transferring means for carrying in an empty carton and carrying out a filled carton. The lining carrying-in means includes means for holding/releasing a lining and means for drawing up the held lining and transferring the lining into the carton, and has a function of packing the upright bundles of the rectangular articles in the carton in a plurality of layers.
• Further, in one form of the apparatus according to the present invention, the apparatus includes a rotating mechanism for reversing the direction of the upright aligned bundle of the rectangular articles such that the bundle is oriented as desired.
Effects of Invention
• The rectangular article boxing method of the present invention transfers the upright aligned bundle of the rectangular articles using the multi-axis actuator and the hand and causes the first guide and the second guide to function. Consequently, it is possible to keep a stable alignment property in an upright form in the carton without using manpower and without binding the conveyed bundle of the rectangular articles and perform consistently and completely automated boxing of the bundle of the rectangular articles. Therefore, it is possible to reduce product costs through manpower saving.
• The rectangular article boxing apparatus of the present invention includes the aligning device, the hand, the multi-axis actuator of the hand, the first guide and the second guide, and the mechanism for controlling drive of the first guide and the second guide. Therefore, it is possible to actuate the first guide and the second guide to respectively play predetermined functions. It is possible to keep a stable alignment property in an upright form in the carton without using manpower and without binding the conveyed bundle of the rectangular articles and perform consistently and completely automated boxing of the bundle of the rectangular articles.
• In one form of the apparatus according to the present invention, the first guide and the second guide are formed in the L shapes opposed to each other. The opposing portions of the first guide and the second guide are formed in the comb teeth shape. Therefore, the first guide and the second guide can be displaced and crossed without interfering with each other. With this form, it is possible to box the upright bundle of the rectangular articles while keeping a stable state in a work process.
• In one form of the apparatus according to the present invention, the apparatus includes the lining carrying-in means in the vicinity of the carton transferring means for carrying in an empty carton and carrying out a filled carton. The lining carrying-in means includes the means for holding/releasing the lining and means for drawing up the held lining and transferring the lining into the carton. Therefore, it is possible to pack the upright bundles of the rectangular articles in the carton in a plurality of layers without using manpower.
• Further, in one form of the apparatus according to the present invention, the apparatus includes a reversing mechanism for reversing the direction of the upright aligned bundle of the rectangular articles such that the bundle is oriented as desired. Consequently, it is possible to pack the bundle of the rectangular articles in the carton in any form.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a schematic diagram for explaining a process for boxing a bundle of rectangular articles of the present invention.
• FIG. 2 is a diagram showing an embodiment of the present invention in which the bundle of the rectangular articles is boxed.
• FIG. 3 is a diagram for explaining a procedure of the present invention for boxing the bundle of the rectangular articles in a carton.
• FIG. 4 is a diagram showing lining sheet carrying-in means used in an apparatus of the invention.
• FIG. 5 is a diagram showing another embodiment of an aligning device in the apparatus of the present invention.
• FIG. 6 is a diagram showing an example of a form in which the bundle of the rectangular articles is boxed according to the present invention.
• FIG. 7 is a diagram showing a conventional pouch automatic packing apparatus.
REFERENCE SINGS LIST
• 1 Stacker
• 2 Pouch bundle
• 3 Hand
• 4 Multi-axis actuator
• 5 First guide
• 6 Second guide
• 7 Carton transferring means
• 8 Aligning device
• 81,81′ Rectangular frames
• 82,82′ Axes
• 8383′ Shafts
• 85 Lever
• 86,86′ Driving devices
• 87 Substrate
• 9 Rotating mechanism
• 10 Pouch manufacturing machine
• 11 Sheet carrying-in means
• 11aVacuum pad
• 11bUp-down direction actuator
• 11cHorizontal direction actuator
MODES FOR CARRYING OUT THE INVENTION
• A process for boxing a bundle of rectangular articles according to the present invention is explained with reference toFIG. 1. Packaging pouches are shown as an example of the rectangular articles. In the figure,reference numeral10 denotes a pouch manufacturing machine of a manufacturing line and1 denotes a stacker. A predetermined number of the packaging pouches discharged from thepouch manufacturing machine10 are stacked by thestacker1 as apouch bundle2. Subsequently, thepouch bundle2 descends and is, after being inserted into an aligningdevice8 by a not-shown pusher, rotated to be an upright and aligned state. Thepouch bundle2 in the upright and aligned state is gripped at an upper end portion by ahand3 and conveyed to a carton C by a multi-axis actuator4. As explained above, the operation of the multi-axis actuator4 lifts thepouch bundle2 from thestacker1 first and subsequently transfers thepouch bundle2 to an upward position of the carton C, moves thepouch bundle2 downward into the carton C, and inserts thepouch bundle2. Note that a broken line frame in the figure indicates arotating mechanism9 for changing the direction of thepouch bundle2 such that thepouch bundle2 is oriented as desired, when boxing thepouch bundle2. This mechanism is adopted according to necessity.
• FIG. 2 is a diagram showing a first embodiment of an apparatus of the present invention that boxes a bundle of rectangular articles. The rectangular articles handled in this embodiment are packaging pouches of a standing form (a standing pouch). The pouches are manufactured and conveyed by pouch manufacturing machines in two lines.Reference numeral8 denotes an aligning device that turns the insertedpouch bundle2 and erects upright and aligns thepouch bundle2. An upper panel of upper and lower panels configuring the aligningdevice8 is lowered by an air cylinder or the like to compress thepouch bundle2 and turned by rotational driving as appropriate to erect upright and align thepouch bundle2.Reference numeral9 denotes a rotating mechanism for changing the direction of thepouch bundle2 such that thepouch bundle2 is oriented as desired. Therotating mechanism9 is adopted according to necessity.Reference numeral3 denotes a hand that grips thepouch bundle2. Reference numeral4 denotes a multi-axis actuator for carrying thehand3 from an upward position of the aligningdevice8 to the carton C. Further,reference numeral5 denotes a first guide andreference numeral6 denotes a second guide. In this embodiment, thefirst guide5 and thesecond guide6 are formed in L shapes opposed to each other. Opposing portions of thefirst guide5 and thesecond guide6 are formed in a comb teeth shape. A configuration is adopted in which the displacement of thefirst guide5 and the displacement of thesecond guide6 can cross in opposing directions without interfering with each other.Reference numeral7 denotes carton transferring means for carrying in an empty carton C and carrying out a filled carton C.
• Thehand3 staying on standby above thepouch bundle2 in the upright and aligned state in the aligningdevice8 is lowered by the multi-axis actuator4, grips thepouch bundle2, and is driven to ascend again, and subsequently horizontally moves to an upward position where the carton C is placed. Subsequently, thehand3 is driven to descend and inserts thepouch bundle2 into the carton C. Thefirst guide5 and thesecond guide6 include actuators same as the multi-axis actuator4 of thehand3. Driving of thefirst guide5 and thesecond guide6 respectively conforming to procedures is driven by the actuators. Further, thefirst guide5 and thesecond guide6 are formed in L shapes opposed to each other. Opposing portions of thefirst guide5 and thesecond guide6 are formed in a comb teeth shape. A configuration is adopted in which the displacement of thefirst guide5 and the displacement of thesecond guide6 can cross in opposing directions without interfering with each other in a form in which the teeth of one of thefirst guide5 and thesecond guide6 mesh with the teeth of the other.
• A boxing operation performed by this embodiment is explained with reference toFIG. 3. In the figure,reference numeral5 denotes a first guide,6 denotes a second guide, and7 denotes a conveyor that conveys the carton C. First, step1 (S1) in the figure indicates a state in which anew pouch bundle2 is inserted into a gap between thefirst guide5 and thesecond guide6. At this point, in the carton C, a group of the pouch bundles2 inserted before is erected upright and placed close to the sidewall of the carton C. Thefirst guide5 plays a function of supporting the group of the pouch bundles2 not to topple. Thepouch bundle2 inserted anew is separated from the group of the pouch bundles2 inserted before by the presence of thefirst guide5. The pouch bundles2 do not come into contact with each other. Thenew bundles2 are inserted into the carton C from the gap between thefirst guide5 and thesecond guide6 in a stable state.
• Step2 (S2) in the figure indicates a step in which thefirst guide5 is displaced to above theupright pouch bundle2. As shown in the figure, at this point, thepouch bundle2 inserted anew is spaced apart from the group of the pouch bundles2 inserted before without coming into contact the group of the pouch bundles2. Thesecond guide6 is present on the opposite side of thefirst guide5 via thepouch bundle2 inserted anew. Therefore, thepouch bundle2 inserted anew does not topple to the opposite side, although tilting to the side of the group of the pouch bundles2 inserted before.
• Step3 (S3) in the figure indicates a step in which thesecond guide6 is shifted to the right to move thepouch bundle2 inserted anew to a position in contact with the existing group of the pouch bundles2 and the upright state of thepouch bundle2 inserted anew and the group of the pouch bundles2 inserted before are retained.
• Step4 (S4) in the figure indicates a step in which thefirst guide5 is moved to the left exceeding the position of thesecond guide6 while retaining the upright state of the group of the pouch bundles2 by thesecond guide6.
• Subsequently, step5 (S5) in the figure indicates a step in which thefirst guide5 is moved down.
• Step6 (S6) in the figure indicates a step in which, in place of thesecond guide6, thefirst guide5 holds the group of the pouch bundles2 is in the upright state.
• Finally, step7 (S7) in the figure indicates a step in which thesecond guide6 is displaced away from the group of the pouch bundles2 and, to receive the nextnew pouch bundle2, thesecond guide6 is displaced to a position where an interval between thesecond guide6 and thefirst guide5 is a predetermined interval. The operation enters a cycle to newnext step1. This operation is sequentially repeated until a predetermined amount of the pouch bundles2 are packed in the carton C. Automatic packing of the pouch bundles2 is stably performed.
• In the figure, the pouch bundles2 are provided in one stage. However, the same operation can cope with a plurality of stages of the pouch bundles2. Further, it is possible to cope with various packing styles by disposing an additional unit and controlling the direction and the like of pouch bundles.
• An embodiment in which the pouch bundles2 are boxed in the carton C in a plurality of stages is explained. In this case, lining-sheet carrying-inmeans11 shown inFIG. 4 is set in the vicinity of carton transferring means7. Lining sheets S are inserted among the packed plurality of stages of the pouch bundles2 to divide the pouch bundles2. The lining-sheet carrying-inmeans11 is means for placing, every time a stage of thepouch bundle2 is formed in the carton C, placing the lining sheet S on the stage of thepouch bundle2. The lining-sheet carrying-inmeans11 is configured fromvacuum pads11athat grip the lining sheet S, an up-downdirection actuator11bthat transfers thevacuum pads11afrom a stock position of the lining sheet S into the carton C, and a horizontal direction actuator11C.
• Note that, as thevacuum pads11a, bellows are adopted to surely attract the lining sheet S. Although not shown in the figure, to prevent thevacuum pads11afrom attracting a plurality of lining sheets S, it is desirable to independently provide or annex means in which an air blow is disposed on a side to blow the air and form an air layer or means for applying vibration when the lining sheet S is lifted.
• FIG. 5 is a diagram showing another embodiment of the aligningdevice8 in the present invention.
• A rectangular article such as a standing pouch form filled with a liquid cleaning agent or the like and having a spout section is a product in which, in order to improve spout performance of contents, bulging combined with ridge and trough formation is applied to the spout section to swell the spout section. When such packaging pouches with spout sections are simply bundled and boxed, there is a problem in that the spout sections are crushed. The aligningdevice8 in this embodiment is means for solving the problem. The aligningdevice8 sequentially shifts and aligns swelling spout portions of a plurality of pouches with spout sections of a pouch bundle.
• In the aligningdevice8, asubstrate87 is provided and tworectangular frames81,81′ are annexed on thesubstrate87 as a pair on the left and right. Thesubstrate87 is set in a vertical state. The upper long side of the leftrectangular frame81 is fixed to thesubstrate87. The lower long side of the rightrectangular frame81′ is fixed to thesubstrate87.Reference numeral85 denotes a lever and86,86′ denote driving devices. The leftrectangular frame81 is pushed up and driven to be deformed into a parallelogram by the drivingdevice86 as indicated by a broken line. On the other hand, the rightrectangular frame81′ is pushed down and driven to be deformed into a parallelogram by the drivingdevice86′ as indicated by a broken line. As it is seen from the positions of theshafts83,83′, the pouch with the spout section loaded in the leftrectangular frame81 and the pouch with the spout section carried into the rightrectangular frame81′ are symmetrically disposed following a manufacturing line such that the spout section of the former is located on the right side and the spout section of the latter is located on the left side. Further, both of the bundles of the pouches with the spout sections loaded in the left and rightrectangular frames81,81′ are loaded on lower fixed sides by the gravity, thereafter turn thesubstrate87 to a boxing process side of the next process, turn the annexedrectangular frames81,81′ to be directed upward, and thereafter perform the deformation driving into the parallelogram. In this case, when the bundle of the pouches with the spout sections in the leftrectangular frame81 is driven to be deformed into the parallelogram by the drivingdevice86, the bundle of the pouches with the spout sections is pressed against the right side as indicated by a broken line. Therefore, a displacement amount of the bundle of the pouches with the spout sections in therectangular frame81 is large. Disorder of alignment tends to occur in the width direction of the pouches with the spout sections in a moving process of the pressing. In order to prevent the disorder of the alignment, thelever85 is attached the leftrectangular frame81. In the deformation driving into the parallelogram of therectangular frame81, thelever85 presses the bundle of the pouches with the spout sections in therectangular frame81 from the left side. Thelever85 turns from a base point position indicated by a solid line to a position indicated by a broken line in the figure. Thelever85 is present in the base point position when the bundle of the pouches with the spout sections is loaded in therectangular frame81. Before the deformation driving into the parallelogram of therectangular frame81 is started, when an opening on the left short side of therectangular frame81 turns to the broken line position and the deformation driving into the parallelogram is started, thelever85 turns following the deformation of therectangular fame81 into the parallelogram. When the deformation into the parallelogram ends, thelever85 returns to the base point position.
• In this way, when the rectangular article is the pouch with the spout section of the standing form, the swelling spout portions are sequentially shifted to align the bundle of the pouches.
• Further, A ofFIG. 6 shows an example in which the pouch bundles2 are simply laid one on top of the other in two stages and packed in two rows and two stages according to an embodiment of the present invention. B ofFIG. 6 shows an example in which theouch bundles2 are laid one on top of the other in one row and two stages in alternating directions and packed in a form in which the pouch bundles2 are aligned in an oblique row according to another embodiment.

Claims (8)

1. A rectangular article boxing method comprising:

a step of erecting upright and aligning a bundle of rectangular articles, gripping, lifting, transferring, and lowering the bundle using a multi-axis actuator and a hand, and inserting the bundle between a first guide and a second guide disposed at a predetermined interval in a carton;

a step of displacing the first guide to above the upright bundle;

a step of moving the inserted bundle to a position in contact with the existing bundle and holding the bundles with the second guide;

a step of holding the upright bundles with the first guide in place of the second guide; and

a step of displacing the second guide to a position at the predetermined interval from the first guide to receive the bundle to be conveyed next.

2. A rectangular article boxing apparatus comprising:

an aligning device that erects upright and aligns a bundle of rectangular articles;

a hand that grips the upright bundle;

a multi-axis actuator that lifts the hand and transfers the hand to a carton placing position and lowers the hand;

a first guide and a second guide disposed at a predetermined interval in a carton; and

a mechanism for controlling drive of the first guide and the second guide such that the first guide is displaced to above the upright bundle, the second guide moves the inserted bundle to a position in contact with the existing bundle and holds the bundles, subsequently the first guide holds the upright bundles in place of the second guide, and the second guide is displaced to a position at the predetermined interval from the first guide to receive the bundle to be conveyed next.

3. The rectangular article boxing apparatus according toclaim 2, wherein the first guide and the second guide are formed in L shapes opposed to each other, and opposing portions of the first guide and the second guide are formed in a comb teeth shape such that the displacement of the first guide and the displacement of the second guide can cross without interfering with each other.

4. The rectangular article boxing apparatus according toclaim 2, further comprising lining carrying-in means in a vicinity of carton transferring means for carrying in an empty carton and carrying out a filled carton, wherein

the lining carrying-in means includes means for holding/releasing a lining and means for drawing up the held lining and transferring the lining into the carton, and has a function of packing the upright bundles of the rectangular articles in the carton in a plurality of layers.

5. The rectangular article boxing apparatus according toclaim 3, further comprising lining carrying-in means in a vicinity of carton transferring means for carrying in an empty carton and carrying out a filled carton, wherein

the lining carrying-in means includes means for holding/releasing a lining and means for drawing up the held lining and transferring the lining into the carton, and has a function of packing the upright bundles of the rectangular articles in the carton in a plurality of layers.

6. The rectangular article boxing apparatus according toclaim 2, further comprising a rotating mechanism for reversing the direction of the upright aligned bundle of the rectangular articles such that the bundle is oriented as desired.

7. The rectangular article boxing apparatus according toclaim 3, further comprising a rotating mechanism for reversing the direction of the upright aligned bundle of the rectangular articles such that the bundle is oriented as desired.

8. The rectangular article boxing apparatus according toclaim 4, further comprising a rotating mechanism for reversing the direction of the upright aligned bundle of the rectangular articles such that the bundle is oriented as desired.

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